WO2001075269A2

WO2001075269A2 - Tunnel lining apparatus and method

Info

Publication number: WO2001075269A2
Application number: PCT/CA2001/000430
Authority: WO
Inventors: Lembit Maimets
Original assignee: Link Pipe, Inc.
Priority date: 2000-03-31
Filing date: 2001-03-30
Publication date: 2001-10-11
Also published as: WO2001075269A3; EG22521A

Abstract

An appararus for lining and/or relining conduits and tunnels, including those having dimensions sufficient for accommodating a roadbed or railway bed for the purpose, for example, of providing automobile tunnels or railway and subway tunnels. The apparatus includes not only the materials themselves for lining the inner walls of conduits or earthen tunnels, e.g., but the system to be employed for placing and securing in place the lining materials. The invention also is directed to the method of placing and securing in place the lining materials.

Description

TITLE: Utility Tunnel Lining Apparatus And Method

Cross-Reference to Related Application

The present application is related to United States Patent Application No. 60/193,367, filed March 31 , 2000, the disclosure of which is hereby incorporated-by-reference thereto in its entirety. Technical Field

The present invention relates generally to an apparatus for lining and/or relining conduits and tunnels that are of a sufficient size for human access, including those having dimensions sufficient for accommodating a roadbed or railway bed for the purpose, for example, of providing automobile tunnels or railway and subway tunnels.

The apparatus includes not only the materials themselves for lining the inner walls of conduits or earthen tunnels, e.g., but the system to be employed for placing and securing in place the lining materials. The invention also is directed to the method of placing and securing in place the lining materials. Background Art

Conduits and tunnels employed for transportation purposes are known and are easily accessible. Conduit systems for carrying water or wastewater, for example, and other liquid and fluid conveyance systems, as well as conduit systems that house communication lines, for example, are typically located underground and, in general, are not easily accessible after installation. Over a period of time, such conduit systems become damaged, weakened, or otherwise begin to deteriorate and leak, for example at the joints between adjacent conduit sections. Such deterioration is caused, for example, by the settling of the surrounding earth adjacent the conduit system, by deterioration of the joints themselves over time, and/or by the growth of roots from trees and other plants.

U.S. Patent No. 5,351 ,720, the disclosure of which is hereby incorporated-by-reference thereto in its entirety, describes methods and apparatus for lining or relining conduit systems, such as utility tunnels or sewers, that are located underground wherein a sleeve member is positioned within a conduit to be repaired. The sleeve member comprises a sheet of material having an outer surface and being movable from a coiled pre- installation position, in which the sheet of material generally surrounds a longitudinal axis, to an uncoiled installation position. U.S. Patent No. 5,351 ,720 also discloses methods and apparatus used in the application of grout between the outer wall of the liner sections and the inner wall of the tunnel and discloses various ways in which grout can be put in place, such as by impregnating a porous gasket which is wrapped around a coiled sleeve before the sleeve is located in place at the repair site or by injecting grout between two stop members at the installation site. Presently, tunnel having damaged or eroded walls are repaired by coating the walls with cement mortar. The mortar is applied just as plastering is applied to a house wall. Mechanical means of applying the mortar coating are also used. Disclosure of Invention The present invention provides an apparatus for relining a tunnel comprising: a plurality of panels, including a central ceiling panel and a pair of opposite side panels; the ceiling panel being adapted to be positioned proximate to an upper region of the tunnel, the ceiling panel having a series of longitudinally spaced apart locking members extending along lower edge regions of the ceiling panel; each of the side panels having upper longitudinally extending edges adapted to engage with a respective series of the locking members of the ceiling panel for at least contributing to the maintenance of the ceiling panel as well as the side panels in position.

The apparatus panels can be made of stainless steel or reinforced concrete.

The apparatus further comprises a spacer which is adapted to be positioned between the panels and an inner surface of the tunnel. The spacer can comprise a rubber material.

The present invention also provides a method of relining a tunnel, comprising: positioning a central ceiling panel on a jack, the ceiling panel being adapted to be positioned proximate to an upper region of the tunnel and having a series of longitudinally spaced apart locking members extending along lower edge regions of the ceiling panel; raising the ceiling panel with the jack to a position proximate the upper region of the tunnel; positioning a pair of opposite side panels beneath the ceiling panel, so as to engage the locking members of the ceiling panel; and lowering and removing the jack.

The method further comprises, before the raising the ceiling panel, positioning a spacer against an inner surface of the tunnel. The method further comprises placing grout between the panels and the inner surface of the tunnel. The grout can be a water-reactive material. The water-reactive material is selected from expanding polyurethane grout, water-reactive gel- forming grout, or epoxy hardening grout.

Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing. Brief Description of the Drawings

The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non- limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

FIG. 1a depicts a barren arch tunnel 1 , i.e., a tunnel without a liner.

FIG. lb depicts another embodiment of the present invention in the form of a rectangular culvert.

FIG. 2 depicts curved liner panels 2, 3, and 4 before installation in an arch tunnel.

FIG. 3 depicts jack 6 positioned for positioning and supporting a ceiling liner panel.

FIG. 4 depicts rebounding spacer 8 to be placed on the exterior wall of the liner panels. FIG. 5 depicts tunnel 1 lined with rebounding spacer 8, awaiting the application of the liner panels.

FIG. 6 depicts central (ceiling) liner panel 2 supported on jack 6. FIG. 7 depicts ceiling panel 2 maintained in position, while side panels 3 and 4 are positioned beneath respective bottom edges of ceiling panel 2.

FIG. 8 depicts side panels 3 and 4 positioned against locking members 5 of ceiling panel 26. FIG. 9 depicts a tunnel having both side panels 3 and 4 installed.

FIG. 10 depicts jack 6, which is operated to lower the support from ceiling panel 2

FIG. 11 depicts a completed tunnel section. Best Modes for Carrying Out the Invention The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

FIG. 1a depicts a barren arch tunnel 1 , i.e., a tunnel without a liner. FIG. lb depicts another embodiment of the present invention in form of a rectangular culvert. Planar ceiling liner panel 2a with rebounding spacer 8a is positioned against the ceiling of the rectangular culvert with planar side panels 3a and 4a positioned against the walls of the rectangular culvert and engaging ceiling liner panel 2a. First, ceiling liner panel 2a is lifted until rebounding spacer 8a is compressed sufficiently to allow planar side panels 3a and 4a to be placed under ceiling panel 2a. After installation of side panels 3a and 4a, the support from ceiling panel 2a is removed allowing rebounding spacer 8a to force ceiling panel 2a to settle on planar side panels 3a and 4a. A composition can be injected into the annular space between side panels 3a and 4a and the tunnel wall and any open space left in the annular space between ceiling liner panel 2a and the tunnel ceiling. These compositions are well known to those skilled in the art and are used to fill in the spaces between the panels and the surfaces of the tunnel. The compositions also can form a seal by filling the annular spaces behind the liners, thereby sealing the conduit or tunnel from water leaks. These compositions, include, but are not limited to grouts such as water-reactive expanding polyurethane grout, water-reactive gel-forming grout, epoxy hardening grout, cementitious grout and the like.

When the surrounding soil is water containing sedimentary material, the annular space between the liner and the conduit or tunnel walls is left empty to be filled by infiltrating water carrying soil particles until the space is filled, thereby creating a fossil-like filler.

FIG. 2 depicts curved liner panels 2, 3, and 4 before installation, the larger central liner panel 2 having locking members 5 extending longitudinally along its opposite bottom edge regions. These locking members can be formed in accordance with those made for connecting the longitudinal edges of an uncoiled sleeve in U.S. Patent No. 5,351 ,720. For example, the locking members can be created by means of a computer numerically controlled (CNC) machine by deforming the material of the sleeves at appropriately spaced locations to create projections along the edge regions, as shown, for example, in FIGS. 2 and 8. Alternatively, a tunnel liner can be made of thick material that does not permit easy punching to form a locking member. In that instance, welded or mechanically attached locks may be used.

FIG. 3 depicts jack 6 positioned for receiving a liner, i.e., particularly central liner panel 2. Although scissors-type jack 6 is depicted, having an upwardly projecting curved support 7 for supporting the central liner panel 2 from below, the present invention is not limited to a scissors-type jack but can encompass other supporting and lifting devices that would perform the functions necessary for positioning and supporting the liner panels. Such lifting devices include, but are not limited to, hydraulic jacks, screw type lifting jacks, hydraulic lifts, cranes and the like.

FIG. 4 depicts rebounding spacer 8, which is to be placed on the exterior wall of the liner panels. Rebounding spacer 8 is positioned along the inner wall of tunnel 1 by any appropriate method known to those skilled in the art, including using jack 6. Rebounding spacer 8 can be made of foam rubber or other resilient material. These materials include, but are not limited to, metallic meshes formed from spring steel and the like, foam materials formed in situ on the walls of the tunnels such as polyurethane foams and the like, metallic coils or springs and the like.

The rebounding spacer may comprise pumped-in concrete, or cement grout made with fine aggregate, which is capable of penetrating cracks and holes, if applied under pressure. While not shown, instead of utilizing a rebounding spacer that extends the complete length of the liner panels, it is contemplated that spacing members, such as the stop members of U.S. Patent No. 5,351 ,720, could border the longitudinal end regions of the liner panels, thereby defining a space for receiving grout or filler. The rebounding spacers may also include hangers or spacers similar to the ones used in spacing and locating concrete forms.

FIG. 5 depicts tunnel 1 , which is lined with rebounding spacer 8 and is ready for application of the liner panels.

FIG. 6 depicts central liner panel 2, i.e., the ceiling panel, which is supported on jack 6. Jack 6 is operated to raise ceiling panel 2 until it is centered in place against the top inner wall of tunnel 1.

FIG. 7 depicts ceiling panel 2 maintained in position, with side panels 3 and 4 being brought to a position beneath respective bottom edges of ceiling panel 2. FIG. 8 depicts side panels 3 and 4 positioned against the locking members 5 of ceiling panel 2, to thereby maintain a stress on the panels to assist in retaining the panels in position upon ultimate removal of jack 6.

FIG. 9 depicts a tunnel having both side panels 3 and 4 installed, the complete liner thereby extending from one side of the road bed, around the inner periphery of tunnel 1 , to the opposite side of the road bed.

FIG. 10 depicts jack 6, which is operated to lower the support from ceiling panel 2, so that jack 6 can be removed and repositioned for installing, e.g., additional sets of liner panels to be longitudinally positioned, through the length of the tunnel section. Between longitudinally adjacent lined panel sections, rebounding spacers 8, such as strips of rubber, o-rings made of rubber and other rebounding material, or other sealing material, can be placed. For example, such strips of sealing material can be overlapped one- half its width by one set of panel sections and one-half its width by another, longitudinally adjacent set of panel sections.

The rebounding spacer can be compressed by a lifting mechanism, such as jack 6. Leaving the space between ceiling panel 2 and the tunnel top compressed as the lifting mechanism is removed creates a seal for containing the filler. Alternatively, sealants, such as paste like materials that can cure into tight seals can be used. Alternatively, in place of rubber-like solid materials and liquid sealants that cure into rubber-like material, a filter-like material can be used, thereby allowing soil-bearing water to pass through and forcing the solids to settle in the empty annular space between the liner and the walls of the tunnel.

FIG. 11 depicts a completed tunnel section as shown. Ceiling panel 2 is maintained in position by opposite side panels 3 and 4. Any number of openings can be made in the ceiling panel and/or in the side panels, e.g. either before installation or after, for the purpose of installing lighting, electrical service, electrical communication, and/or providing access for the injection of grout.

The present invention has application in various environments, such as utility tunnels or railway tracks atop the bed of the roadway within a tunnel. The tunnel can be lined with stainless steel liner, in three pieces from one side of the tunnel to the other.

In accordance with another aspect of the present invention, ceiling panel 2 and side panels 3 and 4 can comprise smooth stainless steel liner panels, pre-cast concrete panels, reinforced concrete panels or fiber reinforced resin panels. It is also within the scope of the present invention to utilize other materials of construction or shapes for the panels. For example, such materials of construction could include plastics, aluminum alloys, and the like.

For example, panels can be circumferentially corrugated to increase the effective stiffness and strength of the liner arch and/or the panels can be corrugated peripherally, i.e., from one side of the roadbed to the other, for increased strength and/or for enabling a reduction in the thickness of the material to be used. The panels can be in sections which are joined together to form each side panel 3 and 4 and to form ceiling panel 2.

Alternatively, the panels can be made of hollow or filled hollow panels In accordance with another aspect of the present invention, a prefabricated relining system can be made. Such a system provides easy installation with least possible service interruption, i.e., a quick installation and completion. Also with a pre-fabricated relining system, no special skills are required and the equipment necessary for installation of the relining is available to those skilled in the art.

The equipment can include commercially available cranes, lifting platforms, fork-lifts or the like.

The present invention is an advance over prior art lining and relining techniques in that lining and/or relining of the present invention can be performed at reasonable cost. Further, the finished product, e.g. a lined conduit, is low maintenance and easily serviceable.

The liner of the present invention is durable, has a clean finish, and is long-lasting. In particular, a liner made of stainless steel assures a clean and maintenance-free long-time performance with unmatched low overall cost. It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

Claims

I CLAIM:

1. An apparatus for lining or relining a tunnel comprising:

a plurality of panels, including a central ceiling panel and a pair of opposite side panels;

the ceiling panel being adapted to be positioned proximate to an upper region of the tunnel, the ceiling panel having a series of longitudinally spaced apart locking members extending along lower edge regions of the ceiling panel;

each of the side panels having upper longitudinally extending edges adapted to engage with a respective series of the locking members of the ceiling panel for at least contributing to the maintenance of the ceiling panel as well as the side panels in position.

2. The apparatus according to claim 1 , wherein the panels are made of stainless steel.

3. The apparatus according to claim 1 , wherein the panels are made of reinforced concrete.

4. The apparatus according to claim 1 , further comprising a spacer adapted to be positioned between the panels and an inner surface of the tunnel.

5. The apparatus according to claim 4, wherein the spacer comprises a rubber material.

6. A method of lining or relining a tunnel, comprising:

positioning a central ceiling panel on a jack, the ceiling panel being adapted to be positioned proximate to an upper region of the tunnel and having a series of longitudinally spaced apart locking members extending along lower edge regions of the ceiling panel; raising the ceiling panel with the jack to a position proximate the upper region of the tunnel;

positioning a pair of opposite side panels beneath the ceiling panel, so as to engage the locking members of the ceiling panel; and

lowering and removing the jack.

7. The method according to claim 6, further comprising, before the raising the ceiling panel, positioning a spacer against an inner surface of the tunnel.

8. The method according to claim 6, further comprising, placing grout between the panels and the inner surface of the tunnel.

9. The method according to claim 8, wherein the grout is a water- reactive material.

10. The method according to claim 8, wherein the water-reactive material is selected from expanding polyurethane grout, water-reactive gel- forming grout, or epoxy hardening grout.